Integrated Disc Dial Leveler Table Base &amp; Levelers

ABSTRACT

The Integrated Disc Leveler Base is a new type of table base that can be used most commonly in the hospitality and corporate settings. This table base allows the user to quickly adjust the pitch, and stability of the table with a “Disc” and “Captive Nut” invention that is not seen on any other table base. Floors are almost never completely level so, in nearly all settings, any table will wobble and not be level without adjustment. When the table is moved even slightly it will need to be adjusted again. The Integrated Disc Table base allows smooth, precise and simple adjustment so when a table is moved it can made level and stabilized with-out having to tilt, lift, slide, or turn the table. It can also be adjusted when the table is full of food and beverage and with substantial weight on it.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application No. 62/311,163, filed Mar. 21, 2016 andentitled “Drill Through Table Base Leveling and Stabilization DeviceSystem,” U.S. Provisional Patent Application No. 62/324,725, filed Apr.19, 2016 and entitled “Flat Foot ‘Quick Adjust’ Table base leveling andStabilization Device,” and to U.S. Provisional Patent Application No.62/283,340, filed Sep. 1, 2016 and entitled “Flat Foot ‘Disc’ Table Base‘Replacement’ Leveler.”

BACKGROUND OF THE INVENTION

This invention is designed to allow the user to easily and withoutdisturbing, tilting, rotating or turning upside down, stabilize and makelevel, tables table bases. It is most applied to tables of the type thatare most commonly found in restaurant, business or commercialenvironments. The original design of the type of table base is typicallyreferred to as “Cross”, “X” or Round” bases and are usually casted invarious sizes and lengths. They can be referred to in other terms.

The origin of this style of base goes back to 1958 when Franklin Jacobsinvented and, soon after along with other companies began to activelysell these bases to restaurants and other business. Franklin Jacobs'company became Falcon Products and at its peak its market share wasestimated at 70%. Today there are an estimated 6,000 table bases of asimilar design sold each day.

FIGS. A-D are photographs of the typical “X” and “Round” table bases asthey were originally designed and are still sold today:

The evolution of my invention.

The “Integrated Disc Dial leveler base” originated from myself (Bruce T.Ringgenberg) due to the frustration of managing the tables inrestaurants that I owned and managed. Although there are other adjunctsolutions available for stabilizing tables, they either didn't work atall or were not durable or were not integrated into the base. I wasseeking, not an “Automatic” leveling solution, but an easily adjustableand durable solution that was mechanical but could easily be adjustedwithout disturbing the food and beverage on the table and therebyimmediately eliminating an uneven and wobbly table.

In short I wanted to just reach down and fix the wobble. I also wantedan adjustable table base that could handle the rigors of a barrestaurant setting. No plastic!

The design is intended to allow the user to manage the table positionrelative to the floor (level) and stability by using an adjustment oradjuster that has been previously unavailable in any setting orinvention. The “DISC” or DIAL” is what allows access to the leveler toallow it to be quickly adjusted.

I began with prototypes and then perfected the design to thespecifications in the application.

BRIEF SUMMARY OF THE INVENTION

The “integrated Disc/Dial Leveler Base & Leveler is really twovariations of a design that share a specific feature: THE DISC or DIAL.This is what allows the user to access the levelers that levels and/orstabilizes the table. Typically a leveler is beneath the table base andcan only be adjusted by turning the table upside down or at leastlifting it to such and extent required to relieve the table frompressure.

ALL VARIATIONS OF ALL TYPES OF LEVELERS THAT I HAVE FOUND, EITHER IN THETRADITIONAL MARKETS AND MANUFACTURER'S AND IN OUR PATENT SEARCHES, DONOT HAVE THE ABILITY TO ADJUST THEM WHILE THEY ARE IN POSITION AND WITHA LOAD OF ANY KIND SUCH AS WITH FOOD, BEVERAGE OR OTHER ITEMS ON THETABLE TOP.

ADDITIONALLY, THERE IS NO DEVICE THAT ALLOWS THE LEVELER TO MOVE UP ANDDOWN WITHOUT THE LEVELER ITSELF SPINNING OR TWISTING. THE “DISC”/DIAL”GIVES THE USER. THE ABILITY TO ADJUST THE TABLE WITH WEIGHT ON IT ANDALSO PROVIDES A LEVELER THAT MOVES UP AND DOWN WITHOUT TWISTING ORSPINNING.

From a design perspective the “Disc”/Dial” and the “Captive” nut make myinvention different from any other leveler and/base available or inexistence today.

There are at least two embodiments of the present invention,including: 1) The integrated Disc Leveler Base; and 2) The “Replacement”Disc Levelers. In both variations of the invention the “Disc” or “Dial”Is the method of adjusting and setting the table position and stability.With the “integrated base the “Captive Nut” is the unique designcharacteristic that makes my invention a perfect fit for a patent.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. A-D are photographs of prior art “X” and “Round table bases.

FIG. 1 is a photograph of a slot cut into a casting of a table base, theslot to receive a hex leveling disc.

FIG. 2 is a photograph of a seat for a “D” broach retaining washerformed within the table base.

FIG. 3 is a photograph of a threaded spindle or cam.

FIG. 4 is a photograph of a “D” broach retaining washer.

FIG. 5 is a photograph of a machine thumb disc washer with a “D” broach.

FIG. 6 is a photograph of parts of the integrated disc/dial leveler andthe casting.

FIG. 7 is a photograph of the assembled parts and the casting.

FIG. 8 is a photograph of a thumb disc installed in the casting.

FIG. 9 is a photograph of a machined base leg extension of a fourPronged “x” base which depicts how we modify all of the legs of the fourpronged or “x” base to prepare the base casting for assembly of the fivepieces of the invention.

FIG. 10 is a photograph of the leg extension with a “Disc” inserted intothe slot visible in FIG. 1 prior to insertion of the captive nut. Thisis very unique and is the identifying feature of the invention. The“Captive Nut” makes it possible to move the leveler up and down withoutthe leveler twisting or turning. This in turn allows for smooth, stableand high weight bearing operation. It also allows the leveler to beadjusted from the side and in a static position. It is the secret sauceof my invention.

FIG. 11 is a photograph of the leg extension after insertion of the“Captive Nut.” The “Captive Threaded Nut” is one of the unique designelements of my invention. This is how the user can adjust the levelerwith out it spinning or twisting. It also extends the control of theadjustment to the “disc” because we stamp the disc with a hex to matchthe captive nut.

FIG. 12 is a photograph of a Disc and a Captive Nut and illustrates howthe “captive nut” and the “disc” go together. We stamp the disc with a0.505 Hex so the pieces combine to lock the disc to the “captive Nut”.

FIG. 13 is a photograph of the leg extension with a “Retaining “D”Broach Disc comprising a “Retaining Disc” which is stamped with a “D”shaped broach. This prevents the leveler from floating in the “CaptiveNut” and thereby spinning. Without the “D” broach the leveler would notmove up and down freely in situations when the leveler would not haveany natural friction. The modified leveler then fits in to the broachedsocket.

FIG. 14 is a photograph of the leg extension receiving a ModifiedLeveler. The Leveler is a stock leveler and comes in various sizes andfeatures. The one we use is 5/16-18 thread and we then machine one sideof the stem to match the “D” broach of the “retaining Disc.” It is alsolarger than most levelers and it has a ¾″ extension stem length, whichis longer than most levelers.

FIG. 15 is a photograph of an assembled Leg Extension illustrating thecompleted assembly of one of the leg extensions of the base. We modifyall four legs to give the user better control of the levelers andthereby making it easier to level and stabilize the table. This is withthe leveler fully extended.

FIG. 16 is a photograph of an “integrated Disc Leveler Base” of thepresent invention in a restaurant environment. The irregular tile anduneven floor demonstrates a challenging environment for level and stabletables. A simple adjustment of the Disc base eliminates the unevennessand wobbly aspects of the table.

FIG. 17 is a close up photograph of the completed leveler base showingan “Adjustable Disc” feature of the present invention.

FIG. 18 is a photograph of the 3 Parts of a standard table base set. Ourmanufacturing Partner, Jacobs International sells its standard base as 3pieces. This is a quality feature and it provides as much structuralintegrity as possible. The base and cap are casted steel and the columnis a bigger gauge that other competing bases in the market.

FIG. 19 is a photograph of a number of bases which include theintegrated disc/dial leveler of the present invention and which areassembled and Ready to be attached to the tabletops.

FIG. 20 is another photograph of the completed base installed in arestaurant. It is a pizza shop.

FIG. 21 is a photograph of a “disc” element of another embodiment of theleveler base which is configured to replace the old broken levelers inan existing base. The disc extends outside of the perimeter of many “x”bases and “round bases in the industry.

FIG. 22 is a photograph of the “Replacement Disc Levelers” in a realsetting. With this embodiment, the leveler becomes accessible throughthe use of the disc which is attached to a traditional leveler. The discallows the user to adjust the height without having to reach underneaththe table leg.

FIG. 23 is another photograph of the replacement leveler which isinstalled to the existing ¼×20 threads of a prior art table base.Although the leveler itself does spin, it still allows the user to makeadjustments more readily than traditional levelers.

FIG. 24 provides several views of a leg extension of a table Base of thepresent invention. Since it is only the ends that need modification thisdrawing accommodates the 22″×22″, 30″×30″ and the 36″×36″ “x” bases. Italso accommodates other bases by other manufactures of similar design.

FIG. 25 illustrates discs of embodiments of the present invention whichaccommodate the “Hex Captive Nut” that is inside of the leg extensionand thereby lock the disc to the captive nut so the user can adjust thelevelers from the side and without lifting or moving the base. It isalso the only reason the user can adjust the table height with contentsof higher weight on the table tops.

FIG. 26 illustrates a “Retaining Disc” of the present invention. This isunique in that it is manufactured with a “D” broach to prevent theleveler from floating/spinning when there is no natural friction, i.e.when there is no downward pressure on the leveler it would spin whenbeing adjusted. The “D” broach matches the leveler stem in shape andprevents spinning of the leveler.

FIG. 27 are views of a #4 Stock Nut for the “Captive Nut” feature. It isinstalled in the base and locks the Leveler Disc to the nut and allowsthe user to adjust the leveler with out it twisting or spinning andthereby also provides a high weight limit for the table.

FIG. 28 provides views of a #5 Screw used to fasten the “Retaining Disc”to the leg extension of the base.

FIG. 29 is a photograph of a #6 Leveler which has been modified bycutting a flat side that matches the “D” broach in the “Retaining Disc.”It is 5/16×18×1″ stem for durability and longer stroke. We offer otherlevelers that may have a larger base or longer stroke.

DETAILED DESCRIPTION OF THE INVENTION

My Invention makes possible the LEVELING and STABILIZATION of a tablebase and therefore the table top attached to it, by adjusting a dial ordisc and without lifting, tilting or affecting the contents on the tabletop.

Unlike any other solution for uneven and wobbly tables it is integratedinto the side of the base leg extention.

It is mechanical and therefore very durable. The levelers can bereplaced due to natural wear and tear, if desired, without having to buya whole new base.

List of innovative and unique features:

-   -   1) it is integrated into the side of the base leg    -   2) It can be used/adjusted when the table if full of food and        beverage    -   3) It is mechanical and manufactured of cast iron and steel with        a rubber plastic leveler making it very durable    -   4) The levelers do not spin which gives my invention the ability        to adjust height even with a high amount of weight on the table        and base.    -   5) The Captive nut that is inside of the base leg is steel and        threaded 5/16×18 to allow small but smooth adjustment of the        leveler and therefore height and position of the base and table.    -   6) It allows the user to LEVEL and make STABLE the table base.        i.e.: It can be adjusted to level a table on a sloping AND        uneven floor.

Process Summary

With the manufacture's permission, we take an existing “X” style tablebase and machine the leg extensions to accommodate the 5 parts of theinvention. We partnered with the largest manufacture and distributor inthe industry, JI Base/Jacobs international.

We then assemble the 2 proprietary stamped parts using screws to affixthe “retaining disc.” We then package the base putting the modifiedlevelers in packs and leaving the levelers in the box with instructions.

Purchases can buy online from our cart at www.flatfootbases.com or usingour wholesale distribution channels. We ship the bases using traditionaland existing companies such as USPS, UPS or FED EX. With large orders wemay use LTL shipping.

There are 4 companies involved in the process:

Jacobs International—They machine the bases to accommodate theproprietary partsPeter Forg Manufacturing Inc.—They stamp and black zinc barrel plate theproprietary and unique parts to be assembled and then ship them to St.Louis, Mo.Gabriel Glides—We purchase existing Glides/Levelers.Clark Logistics—Clark Assembles, stores, repackages and then ships theIntegrated Bases of the present invention.

Process Steps Outline

1) Peter Forg Mfg. stamps the 2 proprietary parts.

-   -   a. The “0.505 Hex Disc”    -   b. The “D Broach Retaining Disc”

2) We purchase 3 existing parts

-   -   a. The “Floating Nut” aka hex coupling nut    -   b. Traditional pan screws 10-32×⅜″    -   c. Existing levelers 5/16×18 thread with 1″ stem.

3) We modify the levelers by cutting a flat side

4) At JI Base we machine existing bases to accommodate the parts

5) We ship the parts to St. Louis, Mo. for assembly. The bases and partsare assembled by a third party

6) We repackage the bases assembled but with the levelers removed toprevent breakage during shipment.

7) The purchaser or user only needs to insert the levelers and installthe base to the table as usual.

Note: The component and some of the process can be slightly modified orimproved with additional innovation. The patent should cover minorvariations in the design and manufacture.

1. (canceled)
 2. An integrated leveler for a table base, comprising: aleveler disc in a slot of a leg of the table base; a captive nut in anaperture of the leg, the captive nut including a bore, wherein thecaptive nut is interconnected to the leveler disc; a retaining discinterconnected to the leg; and a leveler including an threadedextension, the threaded extension receivable within the bore of thecaptive nut.